Reusable custom insoles

ABSTRACT

A reusable, customizable shoe-insole having malleable support material configured to assume a first arch-support structure and a first metatarsal-support structure responsively to application of foot pressure of a first user and maintain the first arch-support structure and the first metatarsal-support structure during the absence of foot pressure and assume a new arch-support structure and a new metatarsal-support structure responsively to each new application of foot pressure of additional users.

BACKGROUND OF THE INVENTION

The present invention relates to shoe insoles, and particularly, relatesto custom insoles providing customized arch and metatarsal supportadaptable to a plurality of users; each having different support needs.

As is known, there are various insole designs providing various levelsand types of arch support; some provide universal arch support, whileother also provide customized support tailored to each user. Customizedinsoles typically employ a stiff, single-use material shaped with theaid of heat treatment, computer rendering, foam molding, or acombination of them to match the foot anatomy of each user.

In contrast, some insoles employ a relatively low-viscosity materiallike a gel or a liquid lacking sufficient stiffness to maintain acustomized support geometry without a load being applied.

SUMMARY OF THE INVENTION

According to the teachings of the present invention there is provided aninsole base; and a malleable, arch-support material supported by theinsole base, the arch-support material configured to assume a firstarch-support structure responsively to application of foot pressure of afirst user on the arch-support material and to maintain the firstsupport-structure until foot pressure of a second user is applied to thefirst arch-support structure, wherein the arch support-structurecorresponds to arch geometry between a heel bone and at least onemetatarsal head of each of the first and second users.

According to a further feature of the present invention, thearch-support material is disclosed inside an airtight polymericencasement.

According to a further feature of the present invention, thearch-support material includes malleable clay.

According to a further feature of the present invention, thearch-support material includes polydimethylsiloxane.

According to a further feature of the present invention, the polymericencasement is constructed from a polymer selected from the groupconsisting of polyvinyl chloride, polypropylene, and polyethylene.

There is also provided according to the teachings of the presentinvention, a malleable, metatarsal-support material supported by theinsole base, the metatarsal-support material configured to assume afirst metatarsal-support structure responsively to application of thefoot pressure of the first user on the metatarsal-support and tomaintain the first metatarsal-support structure until foot pressure ofthe second user is applied to the first metatarsal-support structure.

There is also provided according to the teachings of the presentinvention, providing an insole base; and causing a malleablearch-support material to be supported by the insole base so as to enablethe arch-support material to assume a first customized arch-supportstructure responsively to application of foot pressure of a first useron the arch-support material and to maintain the first customizedarch-support structure until foot pressure of a second user is appliedto the first arch-support structure, wherein the first customizedarch-support structure is bound in part by a heel bone and at least onemetatarsal head.

According to a further feature of the present invention, thearch-support material is disclosed inside an airtight polymericencasement.

According to a further feature of the present invention, thearch-support material has a mass of about 30 to 40 grams.

According to a further feature of the present invention, thearch-support material includes malleable putty.

According to a further feature of the present invention, thearch-support material includes polydimethylsiloxane.

According to a further feature of the present invention, the polymericencasement is constructed from a polymer selected from the groupconsisting of polyvinyl chloride, polypropylene, and polyethylene.

According to a further feature of the present invention, there is alsoprovided a causing a malleable metatarsal-support material to besupported by the insole base so as to enable the metatarsal-supportmaterial to assume a first customized metatarsal-support structureresponsively to application of the foot pressure of a first user on themetatarsal-support material and to maintain the first customizedmetatarsal-support structure until foot pressure of the second user isapplied to the first metatarsal-support structure.

According to a further feature of the present invention, there is alsoprovided further a padding layer covering the encasement.

According to a further feature of the present invention, the wherein thepadding layer includes slow rebound foam.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter regarded as the invention is particularly pointed outand distinctly claimed in the concluding portion of the specification.The features, their interaction, operation, and advantages may best beunderstood with reference to the following detailed description in viewof the accompanying drawings in which:

FIG. 1 is schematic view of pressure zones of a sole of a first user;

FIG. 2 is schematic top view of reusable custom insole having malleablesupport material disposed in an encasement, according to an embodiment;

FIG. 3 is schematic cross-sectional view of along section line A-A ofthe insole depicted in FIG. 2, according to an embodiment;

FIG. 4 is schematic top view of reusable custom insole of FIG. 3 withsuperimposed pressure zones of FIG. 1, according to an embodiment;

FIG. 5 is schematic side view of user stepping onto the insole of FIG.4, according to an embodiment;

FIG. 6 is schematic side view of the insole of FIG. 5 after usercustomization of the insole putty of FIG. 5, according to an embodiment;

FIG. 7 is schematic top view of the insole of FIG. 6 after usercompression of the malleable support material of FIG. 5 depictingsupport material borders defined by the high pressure areas applied tothe support material by foot pressure, according to an embodiment;

FIG. 8 is schematic view of a sole of a second user depicting weightdistribution zones; according to an embodiment;

FIG. 9 is schematic top view of superimposed pressure zones of thesecond user superimposed on the insole having a support materialdistribution defined by the pressure zones of the first user, accordingto an embodiment;

FIG. 10 is schematic side view of a second user stepping onto thecustomized insole of FIG. 9, according to an embodiment;

FIG. 11 is schematic side view of the insole of FIG. 9 aftercustomization of the insole putty by the second of FIG. 10, according toan embodiment; and

FIG. 12 is schematic top view of the insole after compression of theinsole putty by the second user of FIG. 11 in which new support materialborders are defined by the high pressure areas of the second user,according to an embodiment.

FIG. 13 is schematic, side view of a variant embodiment of acustomizable insole having both reusable arch and metatarsal supportstructures prior to the application of foot pressure; according to anembodiment;

FIG. 14 is schematic, side view of the insole of FIG. 13 in a customizedstate after application of foot pressure to the insole of FIG. 13 by auser, according to an embodiment;

FIG. 15 is schematic, side view of the variant embodiment of thecustomizable insole in a customized state securing a metatarsal area ofa foot disposed in a high heel shoe; according to an embodiment; and

FIGS. 16 and 17 are schematic, perspective views of the customizableinsole of FIGS. 13 and 14 in non-customized and customized states,respectively; according to an embodiment.

It will be appreciated that for clarity of illustration, elements shownin the figures have not necessarily been drawn to scale and referencenumerals may be repeated in multiple figures to indicate correspondingor analogous elements and well-known methods, procedures, and componentsare omitted for the sake of clarity.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The present invention relates to custom insole adaptable to multipleusers each having his unique anatomical requirements.

The following terminology will be used throughout the document.

“Workable support material”, “support material”, “putty” all refer to ahigh-viscosity, non-elastic support material capable of preserving ashape into which it is formed upon the application of pressure withoutrecoiling when the pressure is removed. The workable support materialdoesn't harden or undergo a reduction of malleability, therebyadvantageously enabling additional shaping upon application of adifferent pressure distribution associated with a second user's foot.Malleable clay based or polydimethylsiloxane-based compounds or otherworkable support materials having similar malleability, non-elasticityand viscosity are included in the scope of the present invention.

In a certain embodiment, the workable support material is implemented aspolyacrylamide, polyethylene glycol (PEG), or in a certain otherembodiment, a combination of such suitable materials are employed.

Following are several non-limiting examples of support materialviscosities as a function of shoe size.

On the men's scale, a US size 10 shoe (43 in European size) the supportmaterial has a viscosity of about 100,000,000 centipoise (cP) with amargin of error of about 20%, for example.

On the woman's scale the support material has a viscosity of about75,000,000 cP with a margin of error of about 20%, for example.

On the children's scale, a US size 8 (25 in European size) the supportmaterial has a viscosity around 30,000,000 cP with a margin of error ofabout 10%, for example. Another example of a child's shoe having a USsize 2 (34 in European size) has a viscosity of about 50,000,000 cP witha margin of error of about 20%, for example.

It should be appreciated that other viscosities providing suchfunctionality are included within the scope of the invention.

As noted, the viscosity of the support material is sufficiently low toenable formation to the relevant sole geometries responsively to theapplication of foot pressure of subsequent users and sufficiently highto preserve each respective customized support structure when the footpressure is removed from the insole.

It should be appreciated that putty exhibits elasticity during shortperiods of load application and is not pronounced during the relativelylong period of time shape forming pressure is applied and is also notpronounced upon removal of the load.

Furthermore, workable support material exhibits non-stick propertieswith Polyvinyl Chloride (PVC) or Thermoplastic Polyurethane (TPU) orother employed in sack or encasements materials containing the workablesupport material so that shape formation will not be inhibited bysticking to the encasement upon application of a load. In a certainembodiments stick between the working support material and theencasement by application of a lubricants on the inner wall of theencasement.

“Heel area”, “heel”, or “heel bone” all refer to the pressure zonecreated by the calcaneus.

“Inner ball area or medial ball area” refers to the pressure zonecreated by the first and second metatarsal heads or just the firstmetatarsal head.

“Outer ball area or lateral ball area” refers to the pressure zonecreated by the combination of the fourth and fifth metatarsal heads orthe fifth metatarsal head.

“Arch” refers to the foot's natural instep area between the heel boneand the first metatarsal head; alternatively, it is referred to as themedial longitudinal arch.

“The lateral longitudinal arch” is the area or zone spanning the heelbone and the fifth metatarsal head.

Without diminishing in scope, the working support material will bediscussed in terms of putty.

FIG. 1 is schematic view of various zones of a foot sole of a first user1A depicted in terms of pressure exerted on a support surface whenstanding. As shown, heel area or heel bone 6A exerts the greatestpressure, followed by inner ball area 3A, outer ball area 4A, laterallongitudinal arch area SA and medial longitudinal arch or instep 2A.Areas designated SA located in areas other than longitudinal arch areaexert about the same degree of pressure on a support surface like thelongitudinal arch area.

FIGS. 2 and 3 are schematic top and transverse, cross-sectional views,respectively, of standard reusable custom insole 10 prior tocustomization. As shown, insole 10 has insole base 11 molded from ethylvinyl acetate (E.V.A), according to an embodiment. In a certainembodiment, base 11 is shaped in accordance with heel geometry 16 andlacks arch support to ensure that maximum foot pressure is applied tothe putty during shaping. It should be appreciated that insole base 11is constructed from polyurethane, thermo-plastic rubber, nitrolpolyvinyl chloride, latex rubber, or a combination of them are includedwithin the scope of the present invention.

As further shown, insole 10 includes putty 12 housed in a polymericencasement or sealed bag 13 disposed on base insole 11 underneath thearch area (2A of FIG. 1) and follows the contour of inner sloping wall14 of insole base 11. Polymeric encasement 13 has sufficient volume toreceive putty 12 as it spreads into a custom shape upon application ofuser weight. Encasement volume is also sized so that putty 12 slightlyoverlaps high pressure zones 6A and 3A prior to a first compression toprevent putty 12 from spreading away from the arch and forminguncomfortable bumps near the edge of encasement 13. Furthermore,encasement 13 prevents putty from spreading into areas in which a seconduser would be unable to return it to the arch when stepping on insole10. It should be appreciated that there always exists an option ofpushing putty 12 into desired with one's hand.

Polymeric encasement 13 may be implemented with a variety of flexibleyet strong polymeric materials like polyvinyl chloride, polypropylene,polyethylene, or various other materials providing such functionality.Furthermore, putty encasements achieved through insole base and toppadding materials are also included within the scope of the presentinvention.

Putty 12 is sufficiently malleable to spread responsively to theapplication of relatively high pressure from heel area 6A and medialball area 3A; but, sufficiently viscous to hold the new shape even whenthe pressure is removed.

In a certain embodiment putty composition includes either a volume or aweight composition of chloroprene 7%, mineral oil 13%, cold factice 8%,and calcium powder 71.5% and in another embodiment Plasticine® isemployed.

In a certain examples, putty 12 has a quantity ranging between about30-40 grams for a man's US size 10 shoe to enable an arch supportstructure having a height of 14 mm and spanning an insole area of about7.0×4.5 cm. In a certain other embodiment, 15-25 grams of putty 12 isemployed to form arch support structure 12A. Metatarsal supportstructure 13A is formed from a quantity of putty ranging between 4-10grams, in a certain non-limiting embodiment.

It should be appreciated that the quantity of support material, itsdistribution, and the size of the associated support materialencasements are a function of ergonomic parameters and are selected toensure proper formation of arch and/or metatarsal support structuresresponsively to the application of each subsequent, user-specific footpressure to insole 20A.

FIG. 3 is schematic cross-sectional view of along section line A-A ofinsole 10 depicted in FIG. 2, according to an embodiment. As depicted,encased putty 12 is covered with a padding layer 16 constructed fromslow rebound foam having a rebound time of over a minute to fullyrebound from compression, according to an embodiment. Typical examplesof rebound foam are, inter alia, viscoelastic polyurethane foam or EVAmodified. It should be appreciated that in certain embodiments, acombination of quick slow rebound foam are employed in padding layer 16.

Padding layer 16 implemented with rebound foam advantageously providesadditional customization to the toes and other low pressure zoneswithout crowding the foot.

Furthermore, slow rebound foam advantageously provides additional footventilation and use of a thicker, more comfortable padding layer 16. Aflexible top fabric (not shown) covering padding layer 16 also conformsto foot geometry. Typical examples of top fabric include cotton,polyester, and polypropylene

FIG. 4 is schematic top view of reusable custom insole 10A depicting thepressure zones associated with a first user relative to insole elements.

As shown, heel area 6A, inner ball area 3A, putty 12 overlap such thatwhen downward pressure is applied to putty 12 by a user a portion of theputty 12 shifts from these high pressure areas to the lower pressureareas; outer ball area 4A, lateral longitudinal arch area SA. Remainingputty 12 forms an arch support structure in accordance with solegeometry defined in part by heel area 6A, medial ball area 3A and innersole wall 14.

FIGS. 5 and 6 are schematic side views of putty compression prior to andafter the application of user weight achieved by stepping onto insole10A. As shown, putty 12 is disposed in its pre-compression position onbase 12 underneath padding layer 16 in alignment with mediallongitudinal arch 18A associated with first user 20A.

In FIG. 6 putty 12A is shifted into a new positon conforming to thegeometry of arch 18A of first user. Putty 12A is bound in part by thehigh pressure applied by heel area as depicted by vector arrows 21A and22A and high pressure applied by the inner ball area as depicted byvector arrows 23A and 24A, according to an embodiment. The encased puttytogether with the absence of hard plastic advantageously providescustomized arch support without sacrificing comfort.

FIG. 7 is schematic top view of the customized putty shape after usercompression. As shown, putty borders are defined by heel area 6A andinner ball area 3A whereas putty 12A has spread beyond the inner lowerpressure boundaries of outer ball area 4A lateral longitudinal arch area5A.

FIG. 8 is schematic view of a sole 1B of a second user depictinganalogues weight distribution zones; heel area 6B, inner ball area 3B,outer ball area 4B, lateral longitudinal arch area 5B and mediallongitudinal arch or instep 2B. As shown, the weigh distribution zonesof sole 1B of a second user have different geometries than thecorresponding zones of the first user.

FIG. 9 is schematic top view of pressure zones of second usersuperimposed on a previously customized insole having a puttydistribution defined by the pressure zones of first user. As shown,putty 12A is no longer bound by heel area 6B and medial ball area 3B.

FIGS. 10 and 11 are schematic side views of re-customization of insole10A to match the sole anatomy of second user.

As shown in FIG. 10, putty 12A is accumulated in accordance with thearch geometry of a first user as shown in FIG. 6. Foot 20B of seconduser has a less arcuate arch 18B thereby rendering first insole 10Aunusable for him in the absence of modification.

As shown in FIG. 11 putty 12B is shifted into a new positon conformingto the geometry of arch 18B of foot 20A of second user. Putty 12B isbound in part by the high pressure applied by heel area as depicted byvector arrows 21B and high pressure applied by the inner ball area asdepicted by vector arrows 26B as the flatter arch of second user's foot20B applies a downward force 25B to form a re-customized arch supportstructure from putty 12B.

This multi-user adaptability has many applications. For example, anunsatisfied customer is able return customized insoles to a storewithout the store suffering a loss because the store has the ability tore-customizes the insoles to the next buyer.

It should be appreciated that customization from a user having a lowarch to one having a high arch requires pushing the putty by into themidsole area opposite the arch so that a new user can then step on theputty to distribute it in accordance with his sole geometry aspreviously described.

FIG. 12 is schematic top view of the customized putty shape aftercompression of a second user. As shown, putty borders are defined byvariant heel area 6B and inner ball area 3B of the second user whereasputty 12B has spread beyond the inner lower pressure boundaries of outerball area 4B lateral longitudinal arch area 5B.

FIG. 13 is schematic, side view of a variant embodiment of acustomizable insole 20A having both reusable arch and metatarsal supportprovisions 12 and 13, respectively, disposed in between sole 11 andpadding layer 16; according to an embodiment. As shown, both putties 12and 13 are in a pre-customized state in their respective encasements(not shown) disposed underneath the arch and the metatarsal area,respectively.

FIG. 14 is schematic, side view of insole 20A in a customized stateafter application of foot pressure to insole 20A. Analogous to the abovedescribed process, applied foot pressure spreads malleable arch supportmaterial and metatarsal support 12A and 13A, respectively, to a point ofeither containment by the high pressure areas of the foot sole and thepolymeric encasements (not shown) or to a threshold spread capacity forthe particular applied foot pressure as indicated by label 13A.

As shown, metatarsal support material 12, is implemented with about30-40 grams of arch support material spanning the mid-heel to themid-metatarsal to advantageously enable contouring to a wide variety ofarch geometries. Foot engagement becomes increasingly significant inhigh heeled shoes in which gravity pulls the foot forward and downwardin the shoe as a function of heel height as shown in FIG. 15.

FIGS. 16 and 17 are schematic, perspective views of the customizableinsole of FIGS. 13 and 14 in non-customized and customized states,respectively; according to an embodiment.

As shown in FIG. 16, encased metatarsal support material 13 is with avolume having a surface area spanning the full width of the metatarsalarea to advantageously provide a wide variety of contouring options inaccordance with metatarsal geometry.

Encased metatarsal support material 13 is disposed on top of encasedarch support material 12; however, it should be appreciated that in acertain embodiment, the order is reversed and arch support material 12is disposed on top of encased metatarsal support material 13. It shouldbe appreciated that in a certain embodiment there is a viscositydifferential between arch support material 12 and the metatarsal supportmaterial 13. In a certain embodiment the viscosity differential isimplemented with arch support material 12 having a great viscositywhereas in another embodiment the metatarsal support material 13 isimplemented with a greater viscosity.

It should also be appreciated that arch and metatarsal support materials12 and 13 are disposed in separate polymeric encasements in the depictedembodiment; however, in another embodiment the polymeric encasement isimplemented as a single unit with separate pouches

As shown in FIG. 17, customized, metatarsal-support material 12Aconstitutes medial and lateral, longitudinal arches of the foot toprovide optimal support. Analogously, customized, metatarsal-supportmaterial 12A, metatarsal-support material 12A constitutes a contouredridge engaging the foot on insole 20A. Such customization enables thefoot to function from heel strike through propulsion at toe off withoutthe impedance of conventional arch support insoles.

It should be appreciated that various combinations of features andmethods not explicitly set forth in one particular embodiment are alsowithin the scope of the present invention.

What is claimed is:
 1. A custom, reusable shoe insole comprising: aninsole base; and a malleable, arch-support material supported by theinsole base, the arch-support material configured to assume a firstarch-support structure responsively to application of foot pressure of afirst user on the arch-support material and to maintain the firstsupport-structure until foot pressure of a second user is applied to thefirst arch-support structure, wherein the arch support-structurecorresponds to arch geometry between a heel bone and at least onemetatarsal head of each of the first and second users.
 2. The customreusable shoe insole of claim 1, wherein the arch-support material isdisclosed inside an airtight polymeric encasement.
 3. The customreusable shoe insole of claim 2, wherein the arch-support material has amass of about 15 to 25 grams
 4. The custom reusable shoe insole of claim2, wherein the arch-support material includes malleable clay.
 5. Thecustom reusable shoe insole of claim 4, wherein the arch-supportmaterial includes polydimethylsiloxane.
 6. The custom reusable shoeinsole of claim 2, wherein the polymeric encasement is constructed froma polymer selected from the group consisting of polyvinyl chloride,polypropylene, and polyethylene.
 7. The custom reusable shoe insole ofclaim 2, further comprising a padding layer covering the encasement. 8.A custom, reusable shoe insole further comprising: a malleable,metatarsal-support material supported by the insole base, themetatarsal-support material configured to assume a firstmetatarsal-support structure responsively to application of the footpressure of the first user on the metatarsal-support and to maintain thefirst metatarsal-support structure until foot pressure of the seconduser is applied to the first metatarsal-support structure.
 9. A methodof constructing a custom, reusable shoe insole, the method comprising:providing an insole base; and causing a malleable arch-support materialto be supported by the insole base so as to enable the arch-supportmaterial to assume a first customized arch-support structureresponsively to application of foot pressure of a first user on thearch-support material and to maintain the first customized arch-supportstructure until foot pressure of a second user is applied to the firstarch-support structure, wherein the first customized arch-supportstructure is bound in part by a heel bone and at least one metatarsalhead.
 10. The method of claim 9, wherein the arch-support material isdisclosed inside an airtight polymeric encasement.
 11. The method ofclaim 9, wherein the arch-support material has a mass of about 30 to 40grams.
 12. The method of claim 11, wherein the arch-support materialincludes malleable putty.
 13. The method of claim 12, wherein thearch-support material includes polydimethylsiloxane.
 14. The method ofclaim 11, wherein the polymeric encasement is constructed from a polymerselected from the group consisting of polyvinyl chloride, polypropylene,and polyethylene.
 15. The method of claim 11, further comprising:causing a malleable metatarsal-support material to be supported by theinsole base so as to enable the metatarsal-support material to assume afirst customized metatarsal-support structure responsively toapplication of the foot pressure of a first user on themetatarsal-support material and to maintain the first customizedmetatarsal-support structure until foot pressure of the second user isapplied to the first metatarsal-support structure.
 16. The customreusable shoe insole of claim 15, further comprising a padding layercovering the encasement.
 17. The custom reusable shoe insole of claim16, wherein the padding layer includes slow rebound foam.